Part No. 240428
CATALOG NO. 6100.52-K
Effective: 3-01-00
Replaces: 3-15-99
®
OPERATING AND
INSTALLATION
INSTRUCTIONS
Models
055B
VERSA
SPA
and
HOT TUB HEATER
This manual should be maintained in legible condition and kept adjacent to the
heater or kept in a safe place for future reference.
WARNING: If the information in these instructions are not followed exactly, a fire or
explosion may result causing property damage, personal injury or death.
— WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor's phone. Follow the gas
supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.
— Installation and service must be performed by a qualified installer, service agency or
the gas supplier.
— Do not store or use gasoline or other flammable vapors and liquids in the vicinity of
this or any other appliance.
Contents
2 PART ONE - Owner's Operating Instructions
2 SECTION 1 / START-UP PROCEDURES
2 Before Start-Up
3 Lighting Instructions & Shut-Off Procedures
(manually lighted pilot MV)
4 Operating Instructions & Shut-Off Procedures
(automatically lighted pilot IID)
5 After Start-Up
5 SECTION 2 / CAUTION
5 SECTION 3 / MAINTENANCE & CARE PROCEDURES
6 Pool & Spa Water Chemistry
6 Winterizing the Pool and Spa Heater
7 PART TWO - Installation / Service Instructions
7 SECTION 1 / RECEIVING EQUIPMENT
7 SECTION 2/GENERAL SPECIFICATIONS
7 SECTION 3 / INSTALLATION INSTRUCTIONS
7 Code Requirements
7 Base Installation
7 Clearances
9 Combustion Air
9 Venting Connections
11 Gas Supply Connections
12 Plumbing for Water Connections
13 Electrical Wiring
17 SECTION 4 / SERVICING INSTRUCTIONS
17 General Location of Controls
17 Control Adjustments / Replacements
18 Pressure Switch
18 Flame Roll-Out Safety Switch
18 High Limit
18 High Limit Removal
18 Pilot Safety
19 Burner Drawer Removal
19 Gas Valve
19 Main Burner & Orifice
19 Pilot Removal & Cleaning
19 Heat Exchanger Removal
20 Desooting Procedure
20 Combustion Chamber Removal
20 Control Immersion Well Replacement
20 Unitherm Governor Replacement
21 SECTION 5 / TROUBLESHOOTING GUIDE
21 Mechanical
22 Electrical MV Units
24 Electrical IID Units
26 SECTION 6 / REPLACEMENT PARTS
1
PART ONE - OWNER'S OPERATING INSTRUCTIONS
SECTION 1 / START-UP PROCEDURES
BEFORE START-UP
BURNERS
Clean main burners and air louvers of dust, lint and
debris. Keep heater area clear and free from com-
bustibles, flammable liquids and chemicals. Do not
obstruct the flow of combustion and ventilating air.
WARNING: IF YOU DO NOT FOLLOW THESE
INSTRUCTIONS EXACTLY, A FIRE OR EXPLO-
SION MAY RESULT, CAUSING PROPERTY DAM-
AGE, PERSONAL INJURY OR LOSS OF LIFE.
FOR YOUR SAFETY - READ BEFORE OPERATING
2
WATER
First thing, insure that system is filled with water
and have pump operating. Water must be flowing
through the heater during operation.
Fig. #8139s
1. STOP! Read the safety information above.
2. Set the thermostat on the lowest setting.
3. Turn On/Off switch to the "Off" position.
4. Remove heater door panel.
5. Push in gas control knob slightly and turn clock-
wise to "Off".
NOTE: Knob cannot be turned from "Pilot" to
"Off" unless knob is pushed in slightly. Do not
force.
6. Wait 5 minutes to clear out any gas. If you then
smell gas, STOP! Follow "B" in the safety
information above. If you don't smell gas, go to
the next step .
7. Locate pilot mounted on the left side of the
burner drawer. For burner drawer location,
see location of control section, page 18.
HONEYWELL
GAS VALVE
MILLIVOLT
ROBERTSHAW
GAS VALVE
MILLIVOLT
A. This appliance has a pilot that must be lighted by
hand. When lighting the pilot, follow these
instructions exactly.
B. BEFORE LIGHTING smell all around the appli-
ance area for gas. Be sure to smell next to the
floor because some gas is heavier than air and
will settle on the floor.
WHAT TO DO IF YOU SMELL GAS:
*Do not try to light any appliance.
*Do not touch any electric switch; do not use any
phone in your building.
*Immediately call your gas supplier from a neigh-
bor's phone. Follow the gas supplier's instruc-
tions.
LIGHTING INSTRUCTIONS
Gas control knobs shown in "Off" position
ROBERTSHAW PILOT
HONEYWELL PILOT
3
LIGHTING INSTRUCTIONS AND SHUT-OFF PROCEDURES
MANUALLY LIGHTED PILOTS
( MILLIVOLT SYSTEM)
CAUTION: Propane gas is heavier than air and will settle on the ground. Since propane can accumulate in
confined areas, extra care should be exercised when lighting propane heaters.
8. Turn knob on gas control counter-clockwise
to "Pilot".
9. Push in control knob all the way and hold in.
Immediately place flame to pilot to light.
Continue to hold control knob in for about 1
minute after the pilot is lighted, release knob
and it will pop back up. Pilot should remain
lighted. If it goes out, repeat steps 5 through 9.
*If knob does not pop up when released, stop
and immediately call your service technician
or gas supplier.
*If the pilot does not stay lit after several tries,
turn the gas control knob to "Off" and call your
service technician or gas supplier.
10. Stand to the side of the heater and turn the gas
control knob counter clockwise to "On".
11. Replace heater door panel.
12. Turn On/Off switch to the "On" position.
13. Set thermostat to the desired setting.
Fig. #8084.0 Fig. #8083.0
Fig. #8081.0
Fig. # 8199
TO TURN OFF GAS TO APPLIANCE
*If you cannot reach your gas supplier, call the
fire department.
C. Use only your hand to push in or turn the gas
control knob. Never use tools. If the knob will not
push in or turn by hand, do not try to repair it. Call
a qualified service technician. Force or attempted
repair may result in a fire or explosion.
D. Do not use this appliance if any part has been
underwater. Immediately call a qualified service
technician to inspect the appliance and to re-
place any part of the control system and any gas
control which has been under water.
4. Push the gas control knob slightly and turn
clockwise to "Off". Do not force.
5. Replace heater door panel.
1. Set the thermostat to the lowest setting.
2. Turn On/Off switch to the "Off" position.
3. Remove heater door panel.
TO TURN OFF GAS TO APPLIANCE
4
1. STOP! Read the safety information above.
2. Set the thermostat to the lowest setting.
3. Turn off all electric power to the appliance.
4. This appliance is equipped with an ignition
device which automatically lights the pilot. Do
not try to light the pilot by hand.
5. Remove heater door panel.
6. Push in gas control knob slightly and turn clock-
wise to "Off".
Knob cannot be turned to "Off" unless it is
pushed in slightly. Do not force.
7. Wait 5 minutes to clear out any gas. If you then
smell gas, STOP! Follow "B" in the safety infor-
mation previously stated. If you don't smell gas,
go to the next step.
Gas control lever shown in the "On" position.
8. Turn gas control knob counterclockwise
to "On".
Gas control knob shown in "ON" position.
OPERATING INSTRUCTIONS
9. Replace heater door panel.
10. Turn on all electrical power to appliance.
11. Set thermostat to desired setting.
12. If the appliance will not operate, follow the
instructions "To Turn Off Gas To Appliance" and
call your service technician or gas supplier.
A. This appliance is equipped with an ignition
device which automatically lights the pilot. Do
not try to light the pilot by hand.
B. BEFORE OPERATING, smell all around the
appliance area for gas. Be sure to smell next
to the floor because some gas is heavier than
air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS:
*Do not try to light any appliance.
*Do not touch any electric switch; do not use
any phone in your building.
*Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
*If you cannot reach your gas supplier, call the
fire department.
C. Use only your hand to push in or turn the
gas control knob. Never use tools. If the
knob will not push in or turn by hand, do not try
to repair it; call a qualified service technician.
Force or attempted repair may result in fire or
explosion.
D. Do not use this appliance if any part has been
under water. Immediately call a qualified service
technician to inspect the appliance and to re-
place any part of the control system and any gas
control which has been under water.
OPERATING INSTRUCTIONS AND SHUT-OFF PROCEDURES
AUTOMATICALLY LIGHTED PILOTS
(ELECTRONIC IGNITION SYSTEMS)
CAUTION: Propane gas is heavier than air and will settle on the ground. Since propane can accumulate in
confined areas, extra care should be exercised when lighting propane heaters.
4. Push in gas control knob slightly and turn
clockwise to "Off".
5. Replace heater door panel.
1. Set the thermostat at the lowest setting.
2. Turn off all the electric power to the appliance if
service is to be performed.
3. Remove heater door panel.
Fig. # 8112
GAS VALVE-IID
AFTER START-UP
Feel the inlet and outlet pipes. Outlet pipe should be
only slightly warmer than the inlet. It should not be hot.
WARNING: Should overheating occur or the gas sup-
ply fail to shut off, turn off the manual gas control valve
to the appliance.
VISUAL INSPECTION
With the heater on, remove the door and make a
visual check of the pilot and burner.
The flame should be blue with a well-defined
pattern.
5
SECTION 2 / CAUTION
Elevated water temperature can be hazardous,
and the U.S. Consumer Product Safety Commission
recommends the following guidelines:
1. Spa or hot tub water temperatures should never
exceed 104°F (40°C). A temperature of 100°F
(38°C) is considered safe for a healthy adult.
Special caution is suggested for young children.
2. Drinking of alcoholic beverages before or during
spa or hot tub use can cause drowsiness which
could lead to unconsciousness and subse-
quently result in drowning.
3. Pregnant women beware! Soaking in water over
102° F (39°C) can cause fetal damage during
the first three months of pregnancy, (resulting in
the birth of a brain damaged or deformed child).
Pregnant women should stick to the 100°F
(38°C) maximum rule.
4. Before entering the spa or hot tub, users should
check the water temperature with an accurate
thermometer; spa or hot tub thermostats may err
in regulating water temperatures by as much as
four degrees Fahrenheit (2.2°C).
5. Persons with a medical history of heart disease,
circulatory problems, diabetes, or blood pres
sure problems should obtain a physician's
advice before using pools or hot tubs.
6. Persons taking medications which induce
drowsiness, such as tranquilizers, antihista
mines, or anticoagulants, should not use spas or
hot tubs.
SECTION 3 / MAINTENANCE
AND CARE PROCEDURES
To be followed one month after start-up and then
semi-annually.
1. Inspect top of heater and draft hood for soot, (a
sticky black substance around finned tubes,
baffle and open flue gas passageways).
CAUTION: Soot may be combustible. Wet sooted
surfaces completely prior to cleaning. Do not use
steel wire brush.
2. Clean main burners and pilot burner of dust and
lint.
3. Inspect and operate all controls, gas valve and
pressure relief valve.
MAIN BURNER FLAME
4" MAX
Fig. # 8144.0
A yellow or "floating" flame indicates restricted air
openings or incorrect orifice size. Should this occur,
shut the heater off and contact your installer or gas
supplier.
WATER PRESSURE SWITCH
A water pressure switch is provided in the heater to
shut off the burners in the event that water supply to the
heater is interrupted. It is very important to verify that
the switch electrically opens and shuts off the gas
valve when water flow to the heater is interrupted.
Otherwise, rapid and severe damage will likely occur to
the heater. (The water pressure switch should be
checked and adjusted for proper operation by a quali-
fied service person at the time of installation and
periodically checked thereafter. Refer to pressure
switch servicing instruction in Section 4 of this manual.)
WARNING: Operation of the heater without water
circulation will cause rapid and severe damage to the
heater.
PILOT BURNER FLAME
4. Make visual check of the burner and pilot flame.
Flame pattern on the main burner and pilot is
indicated in the previous illustration. Yellow
flame means restriction of the air openings.
Lifting or blowing flame indicates high gas
pressure. Low flame means low gas pressure.
Should this occur, shut the heater off and
contact your gas supplier or qualified service
agency.
5. On indoor heaters, clean room intake openings
to assure adequate flow of combustion and
ventilation air.
CAUTION: Combustion air must not be contaminated
by corrosive chemical fumes which can damage the
heater and void the warranty.
6. Keep area around heater clear and free from
combustible materials and other flammable and
corrosive vapors and liquids.
BASIC TIPS IF HEATER WILL NOT FIRE:
1. If you have no electrical power; it may be your
"circuit breakers" have tripped. Try re-setting
them.
2. If you have electrical power but the heater will
not fire
check the following:
3. The time clock must be moved to the "ON"
position.
4. Your pump strainer basket may be full. If so
remove debris.
5. Your filter may be dirty. If so, backwash or
clean filter.
(To tell if your filter is dirty, the gauge pressure
will be higher than usual).
6. The pump may have lost it's prime. It may be
running dry, check the pressure gauge on the
filter. If there is
no pressure; then you are not
moving water (or your gauge is broken). Try to
get the pump to run at it's normal flow rate.
6
POOL & SPA WATER CHEMISTRY
Chemical imbalance can cause severe damage to
your heater and associated equipment. Maintain your
water pH between 7.4 and 7.8 and total alkalinity
between 100 and 150 p.p.m. If the mineral content and
dissolved solids in the water become too high, scale
forms inside the heat exchanger tubes, reducing
heater efficiency and also damaging the heater. If the
pH drops below 7.2, the heater will be severely dam-
aged. This will result in corrosion of the heat ex-
changer. Heat exchanger damage resulting from
chemical imbalance is not covered by the war-
ranty.
COLD WEATHER OPERATION
MODERATE CLIMATE: Heater operation can con-
tinue during short term cold spells. When tempera-
tures are below freezing, flow (continuous pump op-
eration) must be maintained.
CAUTION: Do not use the heater to maintain water
temperatures just above freezing or for freeze protec-
tion. When heaters are used during freezing weather
care must be taken to avoid freeze ups. Continuous
pump operation is a must. Additional protection may
be required. The heater is not warranted against
freeze ups.
COLD CLIMATE: Prolonged operation with water
temperatures below 50°F is not recommended. When
starting the heater with pool temperatures below 50°F,
operate the heater continuously until higher tempera-
tures are reached. Operating the heater for prolonged
periods with pool water below 50° can seriously dam-
age the heater, and is not covered by the warranty.
For cold climate areas please follow the winterizing
procedures listed below.
WINTERIZING THE SPA HEATER
When heaters installed outdoors in freezing cli-
mate areas are to be shut down for the winter, observe
the following step-by-step procedure:
1. Turn off gas valve, manual gas valve, and electri-
cal supply to the heater.
2. Open drain cock located on the return header.
3. Disconnect compression fittings from the pressure
switch and header that connect to the 1/4"
copper tube and allow the tube to drain.
PART 2 - INSTALLATION / SERVICE INSTRUCTIONS
SECTION 1 / RECEIVING EQUIPMENT
On receipt of your equipment it is suggested that you
visually check for external damage to the carton. If the
carton is damaged, a note should be made on the Bill of
Lading when signing for equipment. Remove the heater
from the carton and if it is damaged, report the damage
to the carrier immediately.
On occasion, we ship some items loose. Be sure that
you receive the number of packages indicated on the Bill
of Lading.
When ordering parts, you must specify model and
serial number of heater. When ordering under warranty
conditions, you must also specify date of installation.
Raypak recommends that this manual be reviewed
thoroughly before installing your Raypak pool/spa
heater. If there are any questions that this manual does
not answer, please contact the factory or your local
Raypak representative.
SECTION 2/GENERAL SPECIFICATION
These heaters are design certified and tested under
the requirements of ANSI Z21.56/CSA 4.7 American
National Standard / CSA standards for gas-fired pool
heaters
The heater is interchangeable and can be used either
indoor or outdoors. The appropriate top designated for
that type of use is required. If desired, the top can be
changed at a later date to change from outdoor to indoor
or vice versa. Millivolt heaters contain a self-generating
electrical system operating between .25 and .75 volts.
AMBIENT TEMPERATURE RATING OF HEATER COM-
PONENTS
Millivolt Heater with Honeywell Gas Valve
+32°F to+175°F
Millivolt Heater with Robertshaw Gas Valve
0°F to +175°F
Electronic Ignition Heaters*
-32°F to +175°F
*Requires 120V or 240V power supply
Rated inputs suitable for up to 2000 feet elevation. For
elevations above 2000 feet, reduce input 4% for each
1000 feet above sea level, as high elevation reduces
combustion performance. For Canada, reduce input
10% when installed at 2000-4500 foot elevation.
7
SECTION 3 / INSTALLATION
INSTRUCTIONS
IMPORTANT NOTICE
These instructions are intended for the use of
qualified personnel only, specifically trained and expe-
rienced in the installation of this type of heating equip-
ment and related system components. Installation and
service personnel may be required by some states to be
licensed. If your state is such, be sure your contractor
bears the appropriate license. Persons not qualified
shall not attempt to fix this equipment nor attempt
repairs according to these instructions.
WARNING: Improper installation, adjustment, altera-
tion, service or maintenance may damage the equip-
ment, create a hazard resulting in asphyxiation, explo-
sion or fire, and will void the warranty.
CODE REQUIREMENTS
NOTE: The heater should not be located in an area
where possible water leakage will result in damage to
the area adjacent to the appliance or to the structure.
When such locations cannot be avoided, it is recom-
mended that a suitable drain pan, adequately drained,
be installed under the appliance. The pan must not
restrict combustion air flow.
Installation must be in accordance with local codes,
or, in the absence of local codes, with the latest editions
of the National Fuel Gas Code, ANSI Z223.1, and the
National Electrical Code, ANSI/NFPA 70. For Canada,
the latest edition of CAN/CGA B-149.1 and B-149.2
BASE INSTALLATION
Heater must be mounted on a level surface. It can
be installed on combustible flooring. Heaters may not
be installed on carpeting.
CLEARANCES
WARNING: The heater shall not be located in an area
where water sprinklers, or other devices, may cause
water to spray through the cabinet louvers and into the
heater. This could cause heavy internal rusting or
damage some electrical components and this would void
the warranty.
8
ALL HEATERS
For clearances from combustible surfaces, see
chart below.
Clearances from Combustible construction.
Indoor Installation:
Top* (Drafthood) - 35"; Vent - 6";
Back - 2"; Right Side - 6";
Left Side - 6"; Floor - 0.
Outdoor Installation:
Top* (Stackless Top) -
unobstructed; Back - 2"; Sides - 6".
* Clearance from Top of Vent Terminal
For servicing, provide at least 24" in front of the
heater for burner tray removal, and at least 18" on the
left side of the heater to inspect and delime the heat
exchanger.
OUTDOOR HEATERS
These heaters are design certified for outdoor
installation, when equipped with the approved top des-
ignated for outdoor use.
Heater with
outdoor Top
Fig. # 8139
WARNING: Do not install within 3 feet of a Heat Pump
or an outdoor condensing unit. Strong air intake from
these equipment can disturb the combustion process
and cause damage or personal injury.
Heaters must not be installed under an overhang of less than three (3) feet from the top of the heater. Three
(3) sides must be open in the area under the overhang. Roof water drainage must be diverted away from the heaters
installed under overhangs with the use of gutters:
For U.S. installations, the point from where the flue products exit the heater must be a minimum of four (4) feet
below, four (4) feet horizontally from or one (1) foot above any door, window or gravity inlet to a building. The top
surface of the heater shall be at least three (3) feet above any forced air inlet, or intake ducts located within ten (10)
feet horizontally.
For installations in Canada, pool heaters shall not be installed with the top of the vent assembly within 10 feet
below, or to either side, of any opening into the building. Refer to the latest revision of CAN/CGA-B149.1 and B149.2.
4
foot
Minimum
4
foot
Minimum
1
foot
Minimum
4
foot
Minimum
3
foot
Minimum
10
foot
Minimum
Forced Air Inlet
U.S. Installation Only
Fig # 8245.1
9
HIGH WIND CONDITIONS (OUTDOOR UNITS ONLY)
In areas where high winds are frequent, it may be
necessary to locate the heater a minimum of 3' from
high vertical walls, or install a wind break so the heater
is not in direct wind current.
INDOOR HEATERS
The design is also certified for indoor installation
when equipped with the approved draft hood. For
Canada, indoor installation is restricted to an enclosure
that is not occupied and does not directly communicate
with occupied area. Refer to the latest edition of CAN/
CGA-B149.1 and B149.2 for specific
requirements.Locate heater as close as practical to a
chimney or gas vent. Heater must always be vented to
the outside. See Vent Piping Section for venting details.
Minimum allowable space is shown on the nameplate.
Heater with
Indoor Top
COMBUSTION AIR (INDOOR UNITS ONLY)
Air For combustion And Ventilation
(Indoor Units Only)
The heater must have both combustion and venti-
lation air. Minimum requirements for net free air supply
openings, one 12 inches from ceiling for ventilation and
one 12 inches from the floor for combustion air as
outlined in the latest edition of the National Fuel Gas Code,
Z223.1(Canada-CAN/CGA-B149.1 and B149.2) and
any local codes that may have jurisdiction.
CAUTION: Combustion air must not be contaminated
by corrosive chemical fumes which can damage the
heater and void the warranty.
a. All Air From Inside The Building:
Each opening shall have a minimum of 50 net free
square inches.
b. All Air From Outdoors:
When air is supplied directly from outside of
building, each opening shall have a minimum of 13
net free square inches.
Fig. # 8138
VENTING CONNECTIONS
VENT TERMINAL (Outdoor)
STEP 1: Remove the (4) screws which fasten
jacket top to heater.
STEP 2: Lower outdoor top onto unit lining up
slots in outdoor top with screw holes in
jacket top.
STEP 3: Reinstall (4) screws to secure jacket top
and outdoor top to unit.
Outdoor Top
Jacket Top
Fig. # 8137
VENT TERMINAL (Indoor)
Locate and assemble as shown. Secure with
screws supplied in envelope inside carton.
Draft Hood
Mounting
Screws
Fig. # 8143
VENT PIPING
WARNING: Indoor boilers require a draft hood that
must be connected to a vent pipe and properly vented
to the outside. Failure to follow this procedure can
cause fire or fatal carbon monoxide poisoning.
Vent piping the same size or larger than the draft
hood outlet is recommended, however, when the total vent
height is at least ten (10) feet (draft hood relief opening
to vent terminal), the vent pipe size may be reduced as
specified in Chapter 10 of the latest edition of the National
Fuel Gas Code, ANSI Z 223. (Canada-CAN/CGA-
B149.1 and B149.2). As much as possible avoid long
horizontal runs of vent pipe and too many elbows. If
installation requires horizontalor or non-vertical runs, the
vent pipe must have a
minimum of 1/4 inch per foot rise
and should be supported at not less than five foot intervals.
Plumbers tape, criss-crossed, will serve to space both
horizontal and vertical piping. Gas vents supported only
by the flashing and extending above the roof more than
five feet should be securely guyed or braced to withstand
snow and wind loads. We recommend use of insulated
vent pipe spacer through the roofs and walls.
For protection against rain or blockage by snow, the
vent pipe must terminate with a vent cap which complies
with the local codes or, in the absence of such codes, to
the latest edition of the National Fuel Gas Code, ANSI
Z223.1-1988 (Canada-CAN/CGA-B149.1 and
B149.2).
The discharge opening must be a minimum of two
feet vertically from the roof surface and at least two feet
higher than any part of the building within ten feet. Vent
stack shall be at least five feet in vertical height above the
draft hood outlet. The vent cap location shall have a
minimum clearance of 4 feet horizontally from, and in no
case above or below, unless a 4-foot horizontal distance
is maintained, from electric meters, gas meters regula-
tors and relief equipment.
The weight of the vent stack or chimney must not rest
on heater draft hood. Support must be provided in
compliance with applicable codes. The heater top and
draft hood must be readily removable for maintenance
and inspection. Vent pipe should be adequately sup-
ported to maintain proper clearances from supported to
maintain proper clearances from combustible construc-
tion.
Type "B" double wall or equivalent vent pipe is
recommended. However single wall metal vent pipe may
be used as specified in the latest edition of the National
Flue Gas Code ANSI Z 223.1-1988 (Canada-CAN/CGA-
B149.1 and B149.2).
10
5' MIN
2' MIN
10' OR LESS
2' MIN
VENT CAP
VENT PIPE
DRAFT HOOD
HEATER
GAS SUPPLY CONNECTIONS
Gas piping must have a sediment trap ahead
of the heater gas controls, and a manual shut-off valve
located outside the heater jacket. All gas piping should
be tested after installation in accordance with local
codes.
CAUTION: The heater and its manual shut off valve
must be disconnected from the gas supply during any
pressure testing of that system at test pressures in
excess of 1/2 psig (3.45 KPA). Dissipate test pressure
in the gas supply line before reconnecting the heater
and its manual shut off valve to gas supply line.
FAILURE TO FOLLOW THIS PROCEDURE MAY
DAMAGE THE GAS VALVE. OVER PRES-
SURED GAS VALVES ARE NOT COVERED BY
WARRANTY. The heater and its gas connections
shall be leak tested before placing the appliance in
operation. Use soapy water for leak test. Do NOT
use open flame.
NOTE: Do not use teflon tape on gas line pipe thread.
A flexible sealant is recommended.
A minimum of 7" W.C. and a maximum of 14" W.C.
upstream pressure under load, and no load conditions
must be provided for natural gas or a minimum of 12"
W. C. and a maximum of 14" for propane gas.
Gas Pressure
Manual Shut
Gas Pressure Test
at Gas Valve
Gas Pressure Test
at Heater
11
Gas Valve
Fig. # 8149.0s
ROBERTSHAW MV W.C Adjustment
HONEYWELL VALVE MV & IID W. C. Adjustment
W.C Adjustment
W.C Adjustment
Fig. # 8199
Fig. # 8081.0
GAS PRESSURE REGULATOR
The gas pressure regulator is preset and sealed at
4" W.C. for natural gas, and ll" W. C. for propane gas.
Between the gas valve and the burners is a l/8" pipe
plug. The pressure at this point, taken with a manome-
ter, should be about 3.7" W. C. natural gas and l0.5"
W.C. propane gas. If an adjustment is needed, remove
seal and turn adjustment screw clockwise to
increase pressure or counter-clockwise to
decrease pressure.
PIPE SIZING FOR GAS CONNECTIONS
MAXIMUM EQUIVALENT PIPE LENGTH
Natural Gas 1000 BTU/ FT . 60 Specific Gravity
@ 0.5" WC Pressure Drop
Propane Gas 2500 BTU/ FT l.53 Specific Gravity
@ 0.5" WC Pressure Drop
1/2" 3/4"
MODEL N P N P
055B 90 200 200 250
3
3
Fig. # 8156
Manual Shut Off Valve
Sediment Trap
12
PLUMBING FOR WATER CONNECTIONS
LOCATION
The VERSA heater requires water flow and posi-
tive pressure to fire and operate properly. It must
therefore be installed downstream of the discharge
side of the filter pump. A typical installation is plumbed
as follows:
1. The inlet side of the filter is plumbed directly
to the discharge side of the filter pump:
2. The outlet side of the filter is then plumbed
to the inlet of the heater; and
3. The outlet of the heater is plumbed to the
return line to the spa. The pump, filter and
heater are thus plumbed in series.
Plumbing from the heater back to the spa must not
have any valves or restriction that could prevent flow
when the pump is operating. To do so will void the
warranty.
Heater must be located so that any water leaks will
not damage the structure of adjacent area. High
temperature plastic pipe (CPVC) may be connected
directly into the heater if local codes permit.
FLOW RATES
PIPE SIZE: 1 1/4"-1 1/2" MIN.GPM: 20, MAX.GPM: 60*
*When flow rates exceed 60 GPM an external auxil-
iary bypass valve is required. See External auxiliary
bypass valve section for details.
COMPANION FLANGE CONNECTIONS
The inlet/outlet header flange accepts a 1 1/2"
copper tube or 1 1/4" galvanized pipe as a slip connec-
tion directly into the manifold. The flange is also
threaded for 1 1/2" pipe thread. 1-1/2" CPVC adapters
(when available) can also be used.
DO NOT use petroleum base assembly fluids
(such as Petroleum Jelly or lubricating oil). If assembly
lube is required, use a silicone base compound, such
as Amoral, etc.
Inlet/Outlet Header
Flange Gasket
Fig.#8158.1
Header Flange
Pipe
Fig. # 8118.0
Outlet Inlet
Unitherm
Governor
CAUTION: Never install PVC directly in header flanges.
The initial connection must be made with a higher
temperature material such as CPVC or Copper. PVC
may be utilized immediately after the initial connection.
AUTOMATIC CHLORINATORS AND CHEMICAL
FEEDERS
All chemicals must be introduced and completely
diluted into the pool or spa water before being circulated
through the heater. Do not place chlorine tablets or
bromine sticks in the skimmer. High chemical concen-
trations will result when the pump is not running (i.e.
overnight).
Chlorinators must feed downstream of the heater
and have an anti-siphoning device to prevent chemical
back-up into the heater when the pump is shut off.
NOTE: High chemical concentration from feeders and
chlorinators that are out of adjustment will cause very
rapid corrosion to the heat exchanger in the heaters.
Such damage is not covered under the warranty.
UNITHERM GOVERNOR OPERATION
The patented Unitherm Governor is a thermostatic
mixing valve specifically designed to maintain constant
heater internal temperature between 105° - 115°F de-
spite continually changing flow rates from the filter and
changing pool temperatures. This narrow range is
needed to prevent damaging condensation on the burn-
ers which will occur if the heater runs for any length of
time below 100°F. It is also needed to inhibit scale
formation in the tubes by maintaining temperatures well
below accelerated scaling temperatures.
throughout its entire length and must pitch downward
from the valve. No shut-off valve shall be installed
between the relief valve and the drain line. Valve lever
should be tripped at least once a year to ensure that
waterways are clear.
ELECTRICAL WIRING
NOTE: If it is necessary to replace any of the original
wiring, it must be replaced with 105 °C wire or its
equivalent, except all black wire must be replaced with
150 °C wire or its equivalent.
MILLIVOLT SYSTEM
The Millivolt System Residential Heater is
equipped with a self-generating electrical system in
which the electric current is provided by means of a
pilot generator. No external electrical connections are
required.
ELECTRONIC INTERMITTENT IGNITION DEVICE
SYSTEM (IID)
NOTE: When the electrical hookup to the heater
requires both 24V and 115V or 240V, each input
voltage must be isolated in separate conduit.
The Electronic Intermittent Ignition Device auto-
matically lights the pilot and main burners upon a call
for the heat. The heater is supplied with a dual voltage
transformer for 120V or 240V input power hookup.
NOTE: IID Propane Units Only
Heater is equipped with an electronic ignition device
with a 100% safety lockout feature. If the heater fails
to start or lockout. Reset the ignition device by inter-
rupting the power to the heater for 60 seconds.
CAUTION: If service replacement of the electronic
ignition device is required. Replace only with a 100%
safety lockout device with 90 second trial for pilot
ignition.
EXTERNAL AUXILIARY BYPASS VALVE
(Where required)
An auxiliary bypass valve should be used when
flow rates exceed 60 GPM (usually a high performance
pump size larger than 1 1/2 HP will exceed this flow
rate). This valve is required to complement the function
of the automatic bypass valve, particularly when start-
ing the heater in winter or early spring when the spa or
pool temperature is down below 55°F. It also serves to
eliminate needless pressure drop through the heater
and accompanying reduction in the flow rate to the spa
jets, etcetera.
From Heater To Heater
To Pool From Pool
Auxiliary Bypass Valve (do not use gate valve)
AUXILIARY BYPASS VALVE ADJUSTMENT
To set bypass: With clean filter, adjustment is
made by feeling the inlet and outlet pipes at the heater.
Outlet pipes should be slightly warmer than inlet and
comfortable to the touch. If pipe is hot, close bypass; if
cold, open bypass
PRESSURE RELIEF VALVE INSTALLATION
To conform to local building codes, it may be
necessary to install a pressure relief valve. A 3/4"
pressure relief valve having a capacity equal to BTU/
HR output of the model to be installed is recommended
for this appliance.
Fig. # 8150.0s
NOTE: To avoid water damage or scalding due to valve
operation, drain pipe must be connected to valve outlet
and run to a safe place of discharge. Drain pipe must be
the same size as the valve discharge connection
Drain Pipe Drain Pipe
Heater Outlet Heater Outlet
Fig. # 8157.0s
13
Fig. # 8929.1
Robertshaw Intermittent
Ignition Device
Honeywell Intermittent
Ignition Device
Fig. # 8085
SPK
14
WIRING DIAGRAM KEY
Fig. # 8096
Fig. # S86/S8600
S86 S8600
PINK CONNECTOR BLUE CONNECTOR
For 120 V input power to the unit, connect the black wire
to the “L1” or hot leg of the power supply. Connect the
white wire to the “L2” or neutral leg of the power supply.
Attach the wire nut to the red wire. There should be no
connection to the red wire for 120V operation.
Fig. #9240
For 240 V input power to the unit, connect the black wire
to the “L1” or hot leg of the power supply. Connect the red
wire to the “L2” or second hot leg of the power supply.
Attach the wire nut to the white wire. There should be no
connection to the white wire for 240V operation.
Fig. # 9241
Heater must be electrically grounded and bonded in
accordance with local codes, or, in the absence of local
codes, with the latest edition of the National Electrical code,
ANSI/NFPA 70 (Canada-Canadian Electrical Code, CSA
C221.1, Part 1 and 2).
NOTE: Input power to the heater (120/240V) should be
supplied from the load (Pump) side of time clock or switch.
Connecting heater to continuous power source will allow
"Fail" indications (service and pressure switch) when pump
is not operating.
WIRING DIAGRAM MILLIVOLT UNITS
WITH MECHANICAL THERMOSTAT
WIRING DIAGRAM MILLIVOLT UNITS
WITH SOLID STATE THERMOSTAT
Fig. # 2246e
Fig. # 1934e
15
16
WIRING DIAGRAM 152178 Model 055 IID
BL
BL
BL
SECTION 4 / SERVICING INSTRUCTIONS
GENERAL LOCATION OF CONTROLS
Drain Valve
Solid State Thermostat &
Ignition Control
Pressure Switch
Burner & Pilot
Thermal Fuse
CONTROLS/ADJUSTMENTS/REPLACEMENTS
CAUTION: Label all wires prior to disconnection when
servicing controls. Wiring errors can cause improper
and dangerous operation. Verify proper operation after
servicing.
DANGER - SHOCK HAZARD -make sure electrical
power to the heater is disconnected to avoid potential
serious injury of damage to components.
TEMPERATURE CONTROLS
The water temperature is controlled by the heater
thermostat on the upper front panel of the heater. The
control center contains an On/Off toggle switch and a
thermostat. The switch functions as a means for turning
the heater on or off.
The thermostat is fitted with a means of limiting the
upper temperature limit below the maximum level. The
knob stop adjustment ring illustrated below is adjust-
able by loosening the set screw, rotating the knobstop
ring to the desired location and retightening the set
screw.
Knobstop Ring Set Screw
PRESSURE SWITCH
The pressure switch, or heater actuator, insures
that the heater operates only when the filter pump is in
operation. It is factory set at 1.75 PSI for deck level
installations. When the heater is located below the level
of the spa or pool, it may be necessary to reset the
pressure switch to compensate for the no-flow static
head. If it is necessary to reset the pressure switch, we
recommend that following procedure:
17
HIGH LIMITS
(Located in the
Inlet/Outlet header)
Fig. # 8160.1s
Gas Valve
Typical
Comfortable
Pool
Temperature
Range
Typical
Comfortable
Spa
Temperature
Range
PRESSURE SWITCH ADJUSTMENT:
1. With pump and heater on, turn adjustment
knob (
clockwise) until a click is heard from the
gas valve.
2. Turn adjustment knob (counter clockwise) 1/4
turn.
3. Turn pump off and on several times. Heater
should shut off immediately. If it does not,
repeat steps above until proper adjustment is
made.
Adjustment Knob
Fig. # 8069.1
Heat Exchanger Height
Heat Exchanger Height
Pool or Spa
Fig. # 8152.0s
NOTE: If heater is installed outside of the limits shown,
a flow switch must be used in place of the pressure
switch when mounted and wired adjacent to the heater.
TWO SPEED PUMPS
In some cases, the flow on the low-speed is insuf-
ficient to operate the heater. This is apparent when the
pressure switch cannot be further adjusted or if the
heater makes banging noises. In these cases, the
pump must be run at high speed when heating the
water.
CAUTION: Do not operate the heater without the func-
tion of a properly adjusted pressure switch.
FLAME ROLL-OUT SAFETY SWITCH
The heater is equipped with a thermal cutoff device
to prevent flame roll-out in the event the heat exchanger
becomes blocked. This is a "Single-use" type fusible
link or thermal fuse, that must be replaced when dis-
abled by an over temperature condition, caused by
excessive restriction in the heat exchanger flue pas-
sage.
Fig. #9177
HIGH LIMITS
The heater is equipped with two automatic high
limits. Set to operate at 135°F and 140°F.
NOTE: An erratic high limit is often characteristic of
internal heat exchanger problem, i.e. scale buildup,
U.G. operation. Refer to troubleshooting section.
Fig. # 8159.0s
HIGH LIMIT REMOVAL
1. Disconnect top portion of unit. (See heat ex-
change removal procedure step 1 thru 7 and
step 10)
2. Remove defective high limit and replace with
new high limit.
3. Reverse above procedure to reinstall.
PILOT SAFETY (Millivolt System)
The heaters equipped with the standing pilot (milli-
volt system), have pilot generators which act as a safety
device to shut off the flow of gas to the main burners and
the pilot burner in case the pilot flame is extinguished.
The pilot burner must be manually relighted to place the
heater in operation again. Refer to the lighting instruc-
tions provided on the heater label.
PILOT SAFETY (IID Units) ELECTRIC IGNITION
The heater employs a pilot safety which closes the
main gas valve within 8/10ths of a second whenever the
pilot flame is interrupted. Pilot flame is automatically lit
when the device is powered. Unit performs its own
safety check and opens the main valve only after the
pilot is proven to be lit.
18
5' Max.
5' Max.
BURNER DRAWER REMOVAL
1. Shut off main electrical power switch to heater.
2. Shut off gas upstream of heater.
3. Remove front door.
4. Disconnect gas line from gas valve.
5. Remove (2) screws that mount burner tray to unit.
6. Disconnect wires that terminate at gas valve, and
thermal fuse.
7. Slide out burner tray.
8. Reverse above procedure to reinstall.
GAS VALVE REMOVAL
1. Remove burner tray. (See burner tray removal
procedure).
2. Disconnect pilot tubing from gas valve.
3. Remove gas valve with manifold from burner tray.
4. Remove manifold from gas valve.
5. Reverse above procedure to re-install.
MAIN BURNER AND ORIFICE REMOVAL
1. Remove burner drawer. (See burner drawer re-
moval procedure).
2. Remove screws and burner hold down bracket.
NOTE: If the heat exchanger is sooted badly, the
burner hold down bracket and spacer can become
distorted from direct flame impingement and this usu-
ally necessitates replacement of these parts.
3. Lift burners from slotted spacers and slide from
orifices. Clean with a wire brush.
4. Orifices usually do not need to be replaced. To
clean, run either copper wire or wood toothpick
through orifice. Do not enlarge hole. To remove
orifice, use a socket wrench and remove from
manifold. DO NOT overtighten when reinstalling.
PILOT REMOVAL AND CLEANING
1. Remove burner drawer. (See burner drawer re-
moval procedure).
2. Disconnect pilot tubing, disconnect wires from gas
valve.
3. Disconnect pilot bracket from burner shield.
4. Remove pilot from bracket.
5. Remove pilot orifice and air opening (Honeywell
MV unit only), and clean with wire or small brush.
CAUTION! DO NOT enlarge hole in pilot orifice.
6. Reverse above procedure to re-install.
Pilot Pilot
Air
Opening
Orifice
Orifice
Fig. # 8045.1
Fig. # 8102.0s
19
HONEYWELL PILOT ROBERTSHAW PILOT
HEAT EXCHANGER REMOVAL
1. Shut water, gas, and electricity off, close valves and
relieve pressure.
2. Drain heat exchanger.
3. Loosen and remove flange bolts.
4. Remove flange and inlet/outlet pipes from the
header. Remove drain valve from rear header
5. Remove outdoor stackless top or indoor stack top
from unit.
6. Remove jacket top, flue collector, and baffle.
7. Remove upper front jacket panel, and disconnect
wires at toggle switch.
8. Remove capillary bulb from inlet/outlet header.
9. Disconnect press switch tube from inlet/outlet
header.
10. Disconnect hi-limit wire from thermostat, and pres-
sure switch.
11. Lift heat exchanger straight up from combustion
chamber, using caution not to damage refractory.
12. Reverse above procedure to re-install.
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